Electron beam induced resonance

ABSTRACT

We describe an ultra-small structure that produces visible light of varying frequency, from a single metallic layer. In one example, a row of metallic posts are etched or plated on a substrate according to a particular geometry. When a charged particle beam passed close by the row of posts, the posts and cavities between them cooperate to resonate and produce radiation in the visible spectrum (or even higher). A plurality of such rows of different geometries can be etched or plated from a single metal layer such that the charged particle beam will yield different visible light frequencies (i.e., different colors) using different ones of the rows.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 11/243,477, filed Oct. 5, 2005, which is a continuation-in-part of U.S. patent application Ser. No. 11/238,991, titled “Ultra-Small Resonating Charged Particle Beam Modulator,” and filed Sep. 30, 2005, the entire contents of both of these applications are incorporated herein by reference. This application is related to U.S. patent application Ser. No. 10/917,511, filed on Aug. 13, 2004, entitled “Patterning Thin Metal Films by Dry Reactive Ion Etching,” and to U.S. application Ser. No. 11/203,407, filed on Aug. 15, 2005, entitled “Method Of Patterning Ultra-Small Structures,” and to U.S. application Ser. No. 11/243,476, titled “Structures And Methods For Coupling Energy From An Electromagnetic Wave,” filed on Oct. 5, 2005, all of which are commonly owned with the present application at the time of filing, and the entire contents of each of which are incorporated herein by reference.

COPYRIGHT NOTICE

A portion of the disclosure of this patent document contains material which is subject to copyright or mask work protection. The copyright or mask work owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright or mask work rights whatsoever.

FIELD OF INVENTION

This disclosure relates to resonance induced in ultra-small metal-layer structures by a charged particle beam.

INTRODUCTION AND BACKGROUND

Electromagnetic Radiation & Waves

Electromagnetic radiation is produced by the motion of electrically charged particles. Oscillating electrons produce electromagnetic radiation commensurate in frequency with the frequency of the oscillations. Electromagnetic radiation is essentially energy transmitted through space or through a material medium in the form of electromagnetic waves. The term can also refer to the emission and propagation of such energy. Whenever an electric charge oscillates or is accelerated, a disturbance characterized by the existence of electric and magnetic fields propagates outward from it. This disturbance is called an electromagnetic wave. Electromagnetic radiation falls into categories of wave types depending upon their frequency, and the frequency range of such waves is tremendous, as is shown by the electromagnetic spectrum in the following chart (which categorizes waves into types depending upon their frequency):

Type Approx. Frequency Radio Less than 3 Gigahertz Microwave  3 Gigahertz-300 Gigahertz Infrared 300 Gigahertz-400 Terahertz Visible 400 Terahertz-750 Terahertz UV 750 Terahertz-30 Petahertz X-ray  30 Petahertz-30 Exahertz Gamma-ray Greater than 30 Exahertz

The ability to generate (or detect) electromagnetic radiation of a particular type (e.g., radio, microwave, etc.) depends upon the ability to create a structure suitable for electron oscillation or excitation at the frequency desired. Electromagnetic radiation at radio frequencies, for example, is relatively easy to generate using relatively large or even somewhat small structures.

Electromagnetic Wave Generation

There are many traditional ways to produce high-frequency radiation in ranges at and above the visible spectrum, for example, up to high hundreds of Terahertz. There are also many traditional and anticipated applications that use such high frequency radiation. As frequencies increase, however, the kinds of structures needed to create the electromagnetic radiation at a desired frequency become generally smaller and harder to manufacture. We have discovered ultra-small-scale devices that obtain multiple different frequencies of radiation from the same operative layer.

Resonant structures have been the basis for much of the presently known high frequency electronics. Devices like klystrons and magnetrons had electronics that moved frequencies of emission up to the megahertz range by the 1930s and 1940s. By around 1960, people were trying to reduce the size of resonant structures to get even higher frequencies, but had limited success because the Q of the devices went down due to the resistivity of the walls of the resonant structures. At about the same time, Smith and Purcell saw the first signs that free electrons could cause the emission of electromagnetic radiation in the visible range by running an electron beam past a diffraction grating. Since then, there has been much speculation as to what the physical basis for the Smith-Purcell radiation really is.

We have shown that some of the theory of resonant structures applies to certain nano structures that we have built. It is assumed that at high enough frequencies, plasmons conduct the energy as opposed to the bulk transport of electrons in the material, although our inventions are not dependent upon such an explanation. Under that theory, the electrical resistance decreases to the point where resonance can effectively occur again, and makes the devices efficient enough to be commercially viable.

Some of the more detailed background sections that follow provide background for the earlier technologies (some of which are introduced above), and provide a framework for understanding why the present inventions are so remarkable compared to the present state-of-the-art.

Microwaves

As previously introduced, microwaves were first generated in so-called “klystrons” in the 1930s by the Varian brothers. Klystrons are now well-known structures for oscillating electrons and creating electromagnetic radiation in the microwave frequency. The structure and operation of klystrons has been well-studied and documented and will be readily understood by the artisan. However, for the purpose of background, the operation of the klystron will be described at a high level, leaving the particularities of such devices to the artisan's present understanding.

Klystrons are a type of linear beam microwave tube. A basic structure of a klystron is shown by way of example in FIG. 1( a). In the late 1930s, a klystron structure was described that involved a direct current stream of electrons within a vacuum cavity passing through an oscillating electric field. In the example of FIG. 1 (a), a klystron 100 is shown as a high-vacuum device with a cathode 102 that emits a well-focused electron beam 104 past a number of cavities 106 that the beam traverses as it travels down a linear tube 108 to anode 103. The cavities are sized and designed to resonate at or near the operating frequency of the tube. The principle, in essence, involves conversion of the kinetic energy in the beam, imparted by a high accelerating voltage, to microwave energy. That conversion takes place as a result of the amplified RF (radio frequency) input signal causing the electrons in the beam to “bunch up” into so-called “bunches” (denoted 110) along the beam path as they pass the various cavities 106. These bunches then give up their energy to the high-level induced RF fields at the output cavity.

The electron bunches are formed when an oscillating electric field causes the electron stream to be velocity modulated so that some number of electrons increase in speed within the stream and some number of electrons decrease in speed within the stream. As the electrons travel through the drift tube of the vacuum cavity the bunches that are formed create a space-charge wave or charge-modulated electron beam. As the electron bunches pass the mouth of the output cavity, the bunches induce a large current, much larger than the input current. The induced current can then generate electromagnetic radiation.

Traveling Wave Tubes

Traveling wave tubes (TWT)—first described in 1942—are another well-known type of linear microwave tube. A TWT includes a source of electrons that travels the length of a microwave electronic tube, an attenuator, a helix delay line, radio frequency (RF) input and output, and an electron collector. In the TWT, an electrical current was sent along the helical delay line to interact with the electron stream.

Backwards Wave Devices

Backwards wave devices are also known and differ from TWTs in that they use a wave in which the power flow is opposite in direction from that of the electron beam. A backwards wave device uses the concept of a backward group velocity with a forward phase velocity. In this case, the RF power comes out at the cathode end of the device. Backward wave devices could be amplifiers or oscillators.

Magnetrons

Magnetrons are another type of well-known resonance cavity structure developed in the 1920s to produce microwave radiation. While their external configurations can differ, each magnetron includes an anode, a cathode, a particular wave tube and a strong magnet. FIG. 1( b) shows an exemplary magnetron 112. In the example magnetron 112 of FIG. 1( b), the anode is shown as the (typically iron) external structure of the circular wave tube 114 and is interrupted by a number of cavities 116 interspersed around the tube 114. The cathode 118 is in the center of the magnetron, as shown. Absent a magnetic field, the cathode would send electrons directly outward toward the anode portions forming the tube 114. With a magnetic field present and in parallel to the cathode, electrons emitted from the cathode take a circular path 118 around the tube as they emerge from the cathode and move toward the anode. The magnetic field from the magnet (not shown) is thus used to cause the electrons of the electron beam to spiral around the cathode, passing the various cavities 116 as they travel around the tube. As with the linear klystron, if the cavities are tuned correctly, they cause the electrons to bunch as they pass by. The bunching and unbunching electrons set up a resonant oscillation within the tube and transfer their oscillating energy to an output cavity at a microwave frequency.

Reflex Klystron

Multiple cavities are not necessarily required to produce microwave radiation. In the reflex klystron, a single cavity, through which the electron beam is passed, can produce the required microwave frequency oscillations. An example reflex klystron 120 is shown in FIG. 1( c). There, the cathode 122 emits electrons toward the reflector plate 124 via an accelerator grid 126 and grids 128. The reflex klystron 120 has a single cavity 130. In this device, the electron beam is modulated (as in other klystrons) by passing by the cavity 130 on its way away from the cathode 122 to the plate 124. Unlike other klystrons, however, the electron beam is not terminated at an output cavity, but instead is reflected by the reflector plate 124. The reflection provides the feedback necessary to maintain electron oscillations within the tube.

In each of the resonant cavity devices described above, the characteristic frequency of electron oscillation depends upon the size, structure, and tuning of the resonant cavities. To date, structures have been discovered that create relatively low frequency radiation (radio and microwave levels), up to, for example, GHz levels, using these resonant structures. Higher levels of radiation are generally thought to be prohibitive because resistance in the cavity walls will dominate with smaller sizes and will not allow oscillation. Also, using current techniques, aluminum and other metals cannot be machined down to sufficiently small sizes to form the cavities desired. Thus, for example, visible light radiation in the range of 400 Terahertz-750 Terahertz is not known to be created by klystron-type structures.

U.S. Pat. No. 6,373,194 to Small illustrates the difficulty in obtaining small, high-frequency radiation sources. Small suggests a method of fabricating a micro-magnetron. In a magnetron, the bunched electron beam passes the opening of the resonance cavity. But to realize an amplified signal, the bunches of electrons must pass the opening of the resonance cavity in less time than the desired output frequency. Thus at a frequency of around 500 THz, the electrons must travel at very high speed and still remain confined. There is no practical magnetic field strong enough to keep the electron spinning in that small of a diameter at those speeds. Small recognizes this issue but does not disclose a solution to it.

Surface plasmons can be excited at a metal dielectric interface by a monochromatic light beam. The energy of the light is bound to the surface and propagates as an electromagnetic wave. Surface plasmons can propagate on the surface of a metal as well as on the interface between a metal and dielectric material. Bulk plasmons can propagate beneath the surface, although they are typically not energetically favored.

Free electron lasers offer intense beams of any wavelength because the electrons are free of any atomic structure. In U.S. Pat. No. 4,740,973, Madey et al. disclose a free electron laser. The free electron laser includes a charged particle accelerator, a cavity with a straight section and an undulator. The accelerator injects a relativistic electron or positron beam into said straight section past an undulator mounted coaxially along said straight section. The undulator periodically modulates in space the acceleration of the electrons passing through it inducing the electrons to produce a light beam that is practically collinear with the axis of undulator. An optical cavity is defined by two mirrors mounted facing each other on either side of the undulator to permit the circulation of light thus emitted. Laser amplification occurs when the period of said circulation of light coincides with the period of passage of the electron packets and the optical gain per passage exceeds the light losses that occur in the optical cavity.

Smith-Purcell

Smith-Purcell radiation occurs when a charged particle passes close to a periodically varying metallic surface, as depicted in FIG. 1( d).

Known Smith-Purcell devices produce visible light by passing an electron beam close to the surface of a diffraction grating. Using the Smith-Purcell diffraction grating, electrons are deflected by image charges in the grating at a frequency in the visible spectrum. In some cases, the effect may be a single electron event, but some devices can exhibit a change in slope of the output intensity versus current. In Smith-Purcell devices, only the energy of the electron beam and the period of the grating affect the frequency of the visible light emission. The beam current is generally, but not always, small. Vermont Photonics notice an increase in output with their devices above a certain current density limit. Because of the nature of diffraction physics, the period of the grating must exceed the wavelength of light.

Koops, et al., U.S. Pat. No. 6,909,104, published Nov. 30, 2000, (§102(e) date May 24, 2002) describe a miniaturized coherent terahertz free electron laser using a periodic grating for the undulator (sometimes referred to as the wiggler). Koops et al. describe a free electron laser using a periodic structure grating for the undulator (also referred to as the wiggler). Koops proposes using standard electronics to bunch the electrons before they enter the undulator. The apparent object of this is to create coherent terahertz radiation. In one instance, Koops, et al. describe a given standard electron beam source that produces up to approximately 20,000 volts accelerating voltage and an electron beam of 20 microns diameter over a grating of 100 to 300 microns period to achieve infrared radiation between 100 and 1000 microns in wavelength. For terahertz radiation, the diffraction grating has a length of approximately 1 mm to 1 cm, with grating periods of 0.5 to 10 microns, “depending on the wavelength of the terahertz radiation to be emitted.” Koops proposes using standard electronics to bunch the electrons before they enter the undulator.

Potylitsin, “Resonant Diffraction Radiation and Smith-Purcell Effect,” 13 Apr. 1998, described an emission of electrons moving close to a periodic structure treated as the resonant diffraction radiation. Potylitsin's grating had “perfectly conducting strips spaced by a vacuum gap.”

Smith-Purcell devices are inefficient. Their production of light is weak compared to their input power, and they cannot be optimized. Current Smith-Purcell devices are not suitable for true visible light applications due at least in part to their inefficiency and inability to effectively produce sufficient photon density to be detectible without specialized equipment.

We realized that the Smith-Purcell devices yielded poor light production efficiency. Rather than deflect the passing electron beam as Smith-Purcell devices do, we created devices that resonated at the frequency of light as the electron beam passes by. In this way, the device resonance matches the system resonance with resulting higher output. Our discovery has proven to produce visible light (or even higher or lower frequency radiation) at higher yields from optimized ultra-small physical structures.

Coupling Energy From Electromagnetic Waves

Coupling energy from electromagnetic waves in the terahertz range from 0.1 THz (about 3000 microns) to 700 THz (about 0.4 microns) is finding use in numerous new applications. These applications include improved detection of concealed weapons and explosives, improved medical imaging, finding biological terror materials, better characterization of semiconductors; and broadening the available bandwidth for wireless communications.

In solid materials the interaction between an electromagnetic wave and a charged particle, namely an electron, can occur via three basic processes: absorption, spontaneous emission and stimulated emission. The interaction can provide a transfer of energy between the electromagnetic wave and the electron. For example, photoconductor semiconductor devices use the absorption process to receive the electromagnetic wave and transfer energy to electron-hole pairs by band-to-band transitions. Electromagnetic waves having an energy level greater than a material's characteristic binding energy can create electrons that move when connected across a voltage source to provide a current. In addition, extrinsic photoconductor devices operate having transitions across forbidden-gap energy levels use the absorption process (S. M., Sze, “Semiconductor Devices Physics and Technology,” 2002).

A measure of the energy coupled from an electromagnetic wave for the material is referred to as an absorption coefficient. A point where the absorption coefficient decreases rapidly is called a cutoff wavelength. The absorption coefficient is dependant on the particular material used to make a device. For example, gallium arsenide (GaAs) absorbs electromagnetic wave energy from about 0.6 microns and has a cutoff wavelength of about 0.87 microns. In another example, silicon (Si) can absorb energy from about 0.4 microns and has a cutoff wavelength of about 1.1 microns. Thus, the ability to transfer energy to the electrons within the material for making the device is a function of the wavelength or frequency of the electromagnetic wave. This means the device can work to couple the electromagnetic wave's energy only over a particular segment of the terahertz range. At the very high end of the terahertz spectrum a Charge Coupled Device (CCD)—an intrinsic photoconductor device—can successfully be employed. If there is a need to couple energy at the lower end of the terahertz spectrum certain extrinsic semiconductors devices can provide for coupling energy at increasing wavelengths by increasing the doping levels.

Surface Enhanced Raman Spectroscopy (SERS)

Raman spectroscopy is a well-known means to measure the characteristics of molecule vibrations using laser radiation as the excitation source. A molecule to be analyzed is illuminated with laser radiation and the resulting scattered frequencies are collected in a detector and analyzed.

Analysis of the scattered frequencies permits the chemical nature of the molecules to be explored. Fleischmann et al. (M. Fleischmann, P. J. Hendra and A. J. McQuillan, Chem. Phys. Lett., 1974, 26, 163) first reported the increased scattering intensities that result from Surface Enhanced Raman Spectroscopy (SERS), though without realizing the cause of the increased intensity.

In SERS, laser radiation is used to excite molecules adsorbed or deposited onto a roughened or porous metallic surface, or a surface having metallic nano-sized features or structures. The largest increase in scattering intensity is realized with surfaces with features that are 10-100 nm in size. Research into the mechanisms of SERS over the past 25 years suggests that both chemical and electromagnetic factors contribute to the enhancing the Raman effect. (See, e.g., A. Campion and P. Kambhampati, Chem. Soc. Rev., 1998, 27 241.)

The electromagnetic contribution occurs when the laser radiation excites plasmon resonances in the metallic surface structures. These plasmons induce local fields of electromagnetic radiation which extend and decay at the rate defined by the dipole decay rate. These local fields contribute to enhancement of the Raman scattering at an overall rate of E4.

Recent research has shown that changes in the shape and composition of nano-sized features of the substrate cause variation in the intensity and shape of the local fields created by the plasmons. Jackson and Halas (J.B. Jackson and N.J. H alas, PNAS, 2004, 101 17930) used nano-shells of gold to tune the plasmon resonance to different frequencies.

Variation in the local electric field strength provided by the induced plasmon is known in SERS-based devices. In U.S. Patent application 2004/0174521 A1, Drachev et al. describe a Raman imaging and sensing device employing nanoantennas. The antennas are metal structures deposited onto a surface. The structures are illuminated with laser radiation. The radiation excites a plasmon in the antennas that enhances the Raman scatter of the sample molecule.

The electric field intensity surrounding the antennas varies as a function of distance from the antennas, as well as the size of the antennas. The intensity of the local electric field increases as the distance between the antennas decreases.

Advantages & Benefits

Myriad benefits and advantages can be obtained by a ultra-small resonant structure that emits varying electromagnetic radiation at higher radiation frequencies such as infrared, visible, UV and X-ray. For example, if the varying electromagnetic radiation is in a visible light frequency, the micro resonant structure can be used for visible light applications that currently employ prior art semiconductor light emitters (such as LCDs, LEDs, and the like that employ electroluminescence or other light-emitting principals). If small enough, such micro-resonance structures can rival semiconductor devices in size, and provide more intense, variable, and efficient light sources. Such micro resonant structures can also be used in place of (or in some cases, in addition to) any application employing non-semiconductor illuminators (such as incandescent, fluorescent, or other light sources). Those applications can include displays for personal or commercial use, home or business illumination, illumination for private display such as on computers, televisions or other screens, and for public display such as on signs, street lights, or other indoor or outdoor illumination. Visible frequency radiation from ultra-small resonant structures also has application in fiber optic communication, chip-to-chip signal coupling, other electronic signal coupling, and any other light-using applications.

Applications can also be envisioned for ultra-small resonant structures that emit in frequencies other than in the visible spectrum, such as for high frequency data carriers. Ultra-small resonant structures that emit at frequencies such as a few tens of terahertz can penetrate walls, making them invisible to a transceiver, which is exceedingly valuable for security applications. The ability to penetrate walls can also be used for imaging objects beyond the walls, which is also useful in, for example, security applications. X-ray frequencies can also be produced for use in medicine, diagnostics, security, construction or any other application where X-ray sources are currently used. Terahertz radiation from ultra-small resonant structures can be used in many of the known applications which now utilize x-rays, with the added advantage that the resulting radiation can be coherent and is non-ionizing.

The use of radiation per se in each of the above applications is not new. But, obtaining that radiation from particular kinds of increasingly small ultra-small resonant structures revolutionizes the way electromagnetic radiation is used in electronic and other devices. For example, the smaller the radiation emitting structure is, the less “real estate” is required to employ it in a commercial device. Since such real estate on a semiconductor, for example, is expensive, an ultra-small resonant structure that provides the myriad application benefits of radiation emission without consuning excessive real estate is valuable. Second, with the kinds of ultra-small resonant structures that we describe, the frequency of the radiation can be high enough to produce visible light of any color and low enough to extend into the terahertz levels (and conceivably even petahertz or exahertz levels with additional advances). Thus, the devices may be tunable to obtain any kind of white light transmission or any frequency or combination of frequencies desired without changing or stacking “bulbs,” or other radiation emitters (visible or invisible).

Currently, LEDs and Solid State Lasers (SSLs) cannot be integrated onto silicon (although much effort has been spent trying). Further, even when LEDs and SSLs are mounted on a wafer, they produce only electromagnetic radiation at a single color. The present devices are easily integrated onto even an existing silicon microchip and can produce many frequencies of electromagnetic radiation at the same time.

There is thus a need for a device having a single layer basic construction that can couple energy from an electromagnetic wave over the full terahertz portion of the electromagnetic spectrum.

GLOSSARY

As used throughout this document:

The phrase “ultra-small resonant structure” shall mean any structure of any material, type or microscopic size that by its characteristics causes electrons to resonate at a frequency in excess of the microwave frequency.

The term “ultra-small” within the phrase “ultra-small resonant structure” shall mean microscopic structural dimensions and shall include so-called “micro” structures, “nano” structures, or any other very small structures that will produce resonance at frequencies in excess of microwave frequencies.

DESCRIPTION OF PRESENTLY PREFERRED EXAMPLES OF THE INVENTION

FIG. 1( a) shows a prior art example klystron.

FIG. 1( b) shows a prior art example magnetron.

FIG. 1( c) shows a prior art example reflex klystron.

FIG. 1( d) depicts aspects of the Smith-Purcell theory.

FIG. 2 is schematic representation of an example embodiment of the invention;

FIG. 3 is another schematic representation of certain parameters associated with light emission from exemplary embodiments of the present invention;

FIG. 4 is a microscopic photograph of an example light-emitting comb structure;

FIG. 5 is a microscopic photograph of a series of example light-emitting comb structures;

FIG. 6 is a microscopic photograph of a series of example light-emitting comb structures;

FIG. 7 is a microscopic photograph of a side view of example series of comb structures;

FIGS. 8 and 9 are closer version microscopic photographs of example light-emitting comb structures;

FIG. 10 is an example substrate pattern used for testing the effect of comb length variations;

FIG. 11 is a microscopic photograph of a side view of an example comb structure;

FIG. 12 is a microscopic photograph of a series of frequency sensitive comb structures;

FIG. 13 is a graph showing example intensity and wavelength versus finger length for some of the series of comb teeth of FIG. 10;

FIG. 14 is a graph showing intensity versus post length for the series of comb teeth of FIG. 10;

FIGS. 15 and 16 are microscopic photographs of dual rows of comb teeth;

FIG. 17 is an example substrate with example dual rows of comb teeth and single rows of comb teeth;

FIGS. 18-20 are further examples of dual rows of comb teeth; and

FIGS. 21-24 are further examples of dual rows of C-shaped structures.

As shown in FIG. 2, a single layer of metal, such as silver or other thin metal, is produced with the desired pattern or otherwise processed to create a number of individual resonant elements. Although sometimes referred to herein as a “layer” of metal, the metal need not be a contiguous layer, but can be a series of elements individually present on a substrate. The metal with the individual elements can be produced by a variety of methods, such as by pulse plating, depositing or etching. Preferred methods for doing so are described in co-pending U.S. application Ser. No. 10/917,571, filed on Aug. 13, 2004, entitled “Patterning Thin Metal Film by Dry Reactive Ion Etching,” and in co-pending U.S. application Ser. No. 11/203,407, filed on Aug. 15, 2005, entitled “Method of Patterning Ultra-small Structures.”

The etching does not need to remove the metal between posts all the way down to the substrate level, nor does the plating have to place the metal posts directly on the substrate (they can be on a silver layer on top of the substrate, for example). That is, the posts may be etched or plated in a manner so a small layer of conductor remains beneath, between and connecting the posts. Alternatively, the posts can be conductively isolated from each other by removing the entire metal layer between the posts. In one embodiment, the metal can be silver, although other metal conductors and even dielectrics are envisioned as well.

A charged particle beam, such as an electron beam 12 produced by an electron microscope, cathode, or any other electron source 10 and passing closely by a series of appropriately-sized structures, causes the electrons in the structures to resonate and produce visible light. In FIG. 2, resonance occurs within the metal posts 14 and in the spaces between the metal posts 14 on a substrate and with the passing electron beam. The metal posts 14 include individual post members 15 a, 15 b, . . . 15 n. The number of post members 15 a . . . 15 n can be as few as one and as many as the available real estate permits. We note that theoretically the present resonance effect can occur in as few as only a single post, but from our practically laboratory experience, we have not measured radiation from either a one post or two post structure. That is, more than two posts have been used to create measurable radiation using current instrumentation.

The spaces between the post members 15 a, 15 b . . . 15 n (FIG. 2) create individual cavities. The post members and/or cavities resonate when the electron beam 12 passes by them. By choosing different geometries of the posts and resonant cavities, and the energy (velocity) of the electron beam, one can produce visible light (or non-visible EMR) of a variety of different frequencies (for example, a variety of different colors in the case of visible emissions) from just a single patterned metal layer.

That resonance is occurring can be seen in FIG. 14. There, the average results of a set of experiments in which the photon radiation from an example of the present invention was plotted (in the y-axis, labeled “counts” of photons, and measured by a photo multiplier tube as detected current pulses) versus the length of the length of the posts 14 that are resonating (in the x-axis, labeled as “finger length”). The intensity versus finger length average plot shows two peaks (and in some experimental results, a third peak was perhaps, though not conclusively, present) of radiation intensity at particular finger lengths. We conclude that certain finger lengths produce more intensity at certain multiple lengths due to the resonance effect occurring within the post 14 itself.

For completeness, the substrate used in the above finger length resonance tests is shown in FIG. 10. There, the lines of posts in the vertical direction correspond to posts of different length from “0” length to 700 nm length. As described in more detail below, the experiment is conducted by passing an electron beam near the rows of posts and generally perpendicular to them (that is, the electron beam passes vertically with respect to FIG. 10). The specifications for the experiment were: a period between posts of 156 nm, a 15 kV beam energy from an electron microscope at 90 degrees to the length of the posts. In that test, a continuous conductive silver substrate layer was beneath the posts. When we repeated the tests, we found that there was some variation in terms of actual intensities seen by the different finger lengths, which we attribute to slight variations in the proximity of the electron beam to the post runs, but the resonance effect was generally apparent in each case.

Notably, the resonance effect described in FIG. 14 appears to occur in the individual posts themselves. That is, it appears that we are recording an effect that occurs from oscillations that are on the surface (including perhaps within) the posts themselves. That resonance is supplementing system resonance, namely the resonance that occurs between adjacent posts. Although these theories do not limit our inventions, we believe that the supplemental resonance occurring within the posts is amplifying the system resonance such that new, substantial levels of intensity are being recognized. As the electron beam passes by the posts, charged particles in the posts begin to resonate between adjacent posts. That resonance produces electromagnetic radiation and is predominantly responsible for the first peak in FIG. 14. What we have now seen is that we can, by choosing finger length, demonstrate further resonance within the fingers themselves (as opposed to between adjacent fingers) that is predominantly responsible for the second peak and is also responsible for amplifying the intensity of the system resonance. We have seen, for example, that without system resonance, then the electron beam cannot be made intense enough to excite the in-post resonance to a detectible level. But, with the system resonance, both the system resonance and the in-post resonance excite the others to further excitation.

We have also detected with angle periodic structures that running the beam one way over the angled teeth produces an effective output while running the beam the other way decreases the output dramatically.

We have also detected that, unlike the general theory on Smith-Purcell, which states that frequency is only dependant on period and electron beam characteristics (such as beam intensity), some of the frequencies of our detected beam change with the finger length. Thus, as shown in FIG. 13, the frequency of the electromagnetic wave produced by the system on a row of 220 nm fingers (posts) has a recorded intensity and wavelength greater than at the lesser shown finger lengths. With Smith-Purcell, the frequency is related to the period of the grating (recalling that Smith-Purcell is produced by a diffraction grating) and beam intensity according to:

$\lambda = {\frac{L}{n} \cdot \left( {\frac{1}{\beta} - {\sin\;\theta}} \right)}$ where λ is the frequency of the resonance, L is the period of the grating, n is a constant, β is related to the speed of the electron beam, and θ is the angle of diffraction of the electron.

It is reasonable to suggest, that if the other modes are aligned to the operating frequency, the Q of the device will be improved. A sweep of the duty cycle of the space width s (shown in FIG. 3) and post width (l-s) indicates that the space width s and period length l have relevance to the center frequency of the resultant radiation. By sweeping the geometries d, l, and s of FIG. 3 and the length of the posts (shown in FIG. 2 and variously at FIG. 10), at given electron velocity v and current density, while evaluating the characteristic harmonics during each sweep, one can ascertain a predictable design model and equation set for a particular metal layer type and construction. With such, a series of posts can be constructed that output substantial EMR in the visible spectrum (or higher) and which can be optimized based on alterations of the geometry, electron velocity and density, and metal type.

Using the above-described sweeps, one can also find the point of maximum Q for given posts 14 as shown in FIG. 14. Additional options also exist to widen the bandwidth or even have multiple frequency points on a single device. Such options include irregularly shaped posts and spacing, series arrays of non-uniform periods, asymmetrical post orientation, multiple beam configurations, etc.

Some example geometries are described herein and are shown in the associated figures. Those geometries do not limit the present inventions, but are described in order to provide illustrative examples of geometries that work for the intended purpose. In FIG. 3, an example representation of our posts is shown with dimensional variables labeled for clarity. As described above, in our devices, for example, as the post length d was swept in length, the intensity of the radiation was oscillatory in nature, aligning very near to the second and third harmonic lengths.

In FIG. 4, a microscopic photograph depicts a set of actual single metal-layer posts, of the kind generally referred to in FIG. 3. In the FIG. 4 example, the metal layer is silver. The metal is pulse plated to provide the posts 14 shown. The posts may be constructed according to the techniques described in the applications identified above under “Related Applications.”

In FIG. 4, the post length is about 698 nm. The space width, s, is about 51.5 nm. The post and space width, 1, is about 155 nm. The electron beam runs perpendicular to the length of the posts and spaces, as shown in FIG. 2. Unlike a Smith-Purcell device, the resultant radiation from a structure such as shown in FIG. 4 is actually intense enough to be visible to the human eye without the use of a relativistic electron beam. Another example set of the structures of FIG. 4 in which the post length was altered to determine the effect on harmonic lengths is shown in FIG. 5. There, four different example post lengths are shown, 303 nm, 349 nm, 373 nm, and 396 nm. The example of FIG. 5 realizes harmonic oscillation aligning near the second and third harmonic lengths ///

As described previously, by altering the combined length, period 1, spaces s, and post members 15 a . . . 15 n, the center frequency of the radiation changes. It is thus valuable to size a row of posts 14 such that a desired frequency of visible light is emitted when the charged particle beam is passed near it. FIG. 6 illustrates an alternative example embodiment in which we produce a variety of frequencies by modifying the post lengths in multiple rows of differently configured posts. By etching, plating or otherwise producing multiple rows of posts, each of which is tuned to a produce a different frequency, multiple colors of visible light can be produced by directing an injected charged particle beam parallel and close to appropriate ones of the rows.

Indeed, we can envision a row of posts having varying lengths within the row itself, such that different frequencies of radiation are excited by different ones or combinations of posts. The result could be a mixed, multiple wavelength light.

Different frequency outputs can also be obtained by directing multiple charged particle beams at different rows of posts etched from or plated on the same metal layer. Thus, one can obtain any color of visible light from a single layer metal nano-or micro-structure. Because the rows are only about a few micrometers or less apart, directing multiple electron beams simultaneously at different ones of the rows could also mix the visible light to yield to the human eye essentially any color frequency in the visible spectrum. The breadth and sensitivity of color options available in such a system is limited only by the number and geometries of the rows, and the number of electron beam sources available to stimulate the rows into resonance.

FIG. 7 illustrates a side view of a set of rows of posts. As shown, each row has a different geometry to produce a different radiation. Various period, space distances, and depths are shown. The lengths of the posts, a dimension clearly shown in the example of FIG. 6, are not clearly identifiable in FIG. 7. In FIG. 7, the period of the second row is 210 nm while the period of the third row is 175 nm. The space of the first row is 123 nm, while the space of the fourth row is 57 nm. Depths and lengths can also be varied. Each of the rows can exhibit different post geometries (although there may be reasons for including some or all rows of duplicate geometries).

As shown in FIG. 6, the post elements 14 do not necessarily have to have the backbone portion connecting the posts, as shown in FIG. 4. The posts on the substrate can resemble a comb with a backbone connecting all of the teeth, as in FIG. 4, or can resemble be just the teeth without the comb backbone, as in FIG. 6. Each post can also be freestanding and physically unconnected to adjacent posts except by the portion of metal layer remaining beneath the posts or by the substrate if the metal layer is completely removed from around the posts. Alternatively, the posts can be connected by remaining metal layer in the form of the backbone shown in FIG. 3 or by a top layer shown in FIG. 11, or by a connecting conductive substrate beneath the posts. In FIG. 11, the posts have period length l of 213 nm, a post width (l-s) of 67.6 nm and a height (d) of 184 nm. The posts are covered by a layer of silver, which can provide advantageous—though not necessary—coupling between the posts (such coupling can also or alternatively be provided by contiguous metal layer left beneath the posts).

FIGS. 8 and 9 illustrate still further example geometries of non-backboned posts 14 are shown. In each case, just two rows are shown, although any number of rows can be employed, from one to any. The number of rows is limited by available real estate on the substrate, except that multiple substrates can also be employed proximate (side-by-side or atop) each other. The specific dimensions shown in FIGS. 8 and 9, like the other examples described herein are just illustrative and not limiting. Sizes and geometries of the posts, numbers of the posts, sequences of the posts, and arrangements of the posts can also be changed and remain within the concepts of the present inventions.

When the backbone is removed, for certain wavelengths, radiation can emit from both sides of the device. Depending on the spacing and the XY-dimensions of the post members, it may be possible that there is a blocking mode that negates the photon emission from that side. The emissions are thus altered by the presence/absence of the backbone, but the existence of resonance remains.

The direction of the radiation can also be adjusted. We have noted that radiation has been detected outwardly from the row (essentially parallel to the long dimension of the posts and spaces), as well as upwardly (relative, for example, to the plane of FIG. 6). It thus appears that some directionality can be advantageously employed for the radiation's initial direction.

Given that plasmon velocity is material dependent, it can be advantageous to build devices using conductive materials other than silver. We expect that less conductive materials would have a lower emission wavelength due to the slower plasmon velocity. Similarly, more conductive material would have higher emission wavelengths. Thus, metal or other conductive layers of different types can be employed. As described above, we envision single metal or alloy layers of different row geometries producing different frequencies. We also envision different metal layer types with the same or different row geometries to produce different frequencies.

FIG. 12 illustrates anther set of post rows (similar to FIG. 10). The rows in FIG. 12 have no backbones on the posts. As can be seen, the different rows are formed of a common metal layer and have different lengths so as to produce different frequencies and intensities of radiation when a charge particle beam passes close to (and generally parallel to) a selected row.

FIGS. 15-17 are still further example configurations of the rows of posts 14. In FIGS. 15 and 16, two rows are provided in proximity, so an electron beam 12 can be passed between the two rows, exciting resonance in each row simultaneously. Each row can have posts of the same geometry or each row can have posts of different geometries. Further, as between the two rows, the geometries of the posts can be entirely the same, some different, or entirely different. If the rows have uniform posts within the row and different posts as between the two rows, then the different rows produce different wavelengths of radiation from a common electron beam.

With the two row embodiments of FIGS. 15-16, detectable light output was increased at least 20% (the increase is likely much more than 20% due to the inability to detect light going in undetected directions from the two rows.

FIG. 17 is a substrate with some two row embodiments, as in FIGS. 15 and 16, with other single row and multiple row example embodiments. In FIG. 17, the dual row embodiments on the left side produced light of two different colors FIGS. 18-20 show some additional details of the dual row embodiments. It is worth noting that simultaneous dual frequency outputs from two rows, like those shown in FIG. 18-20, are not realized with devices operating according to diffraction theory, such as Smith-Purcell devices.

As should be understood from these descriptions, there is a wide variety of geometries of posts, geometries of rows, orientations of posts and rows, kinds of posts, kinds of metal, kinds of substrates, backbones, electron beam characteristics and other criteria that we envision within the framework of our inventions. We envision within our inventions deviations from the above criteria, whether or not specifically described herein. For example, FIGS. 21-24 show still further example resonant structures by which an electron beam can pass to induce resonance in and between. In FIG. 21, the structures are not in the form of straight posts (as in FIG. 1), but are instead C-shaped cavities which can form a type of waveguide. The electron beam passes down the middle of the facing C's, perpendicular to the arms of the Cs. As in FIG. 1, the electron beam induces resonance in the structures, both within the structures (including surface resonance) and among the structures (system resonance) to produce electromagnetic radiation at superior intensities and optimizable wavelengths.

FIG. 21 also illustrates a device that exhibits higher order of harmonics by alternating “half-stubs” between the full stubs. The same kind of idea in which half-stubs are alternated with full stubs can be incorporated into any of the other embodiments (such as the several post embodiments) described earlier in this document. In the case of FIG. 21, the half-stubs are actually half-Cs nestled into the full-Cs, with the electron beam passing near and perpendicular to the arms of each. Resonance occurs within each C, between the nestled and nestling Cs, and between adjacent large Cs. As in previously described embodiments, the period of the repeating Cs is less than the wavelength of light, so the light is not being diffracted because the period spacing is so small that the arms of the Cs (or in the case of the posts, the ends of the posts) appear essentially as a solid “surface” to the wave. In the case of FIG. 21, the period of the respective arms of the Cs is 117 nm. The distance from the end of one arm of a big-C to the other arm of the same big-C is about 797 nm (i.e., it can be greater than the wavelength of light) The length of each big-C arm is about 515 nm.

FIG. 22 illustrates a double rowed, single-C embodiment in which offset, facing Cs are provided with the electron beam running between them. As shown, the period of the repeating arms is about 427 nm. The space within which the electron beam runs is about 40 nm. The width of the C is about 122 nm. The entire length of two facing Cs and the space between is 802 nm.

FIG. 23 illustrates a number of example light-producing embodiments, including nestled-C embodiments and post embodiments. FIG. 24 is a hybrid of the Cs and posts, in which a post is nestled into each C. The posts and C-arms have a period of about 225 nm, with a spacing between the arms of adjacent Cs of about 83 nm. Again, the electron runs down the middle slit to induce resonance in the proximate posts and ends of the C-arms.

All of the structures described operate under vacuum conditions. Our invention does not require any particular kind of evacuation structure. Many known hermetic sealing techniques can be employed to ensure the vacuum condition remains during a reasonable lifespan of operation. We anticipate that the devices can be operated in a pressure up to atmospheric pressure if the mean free path of the electrons is longer than the device length at the operating pressure.

The conductive structures described herein are preferably comprised of silver, but may be any conductive metal or may be any non-metallic conductor such as an ionic conductor. Dielectrics are also envisioned as layer materials in the alternative to conductive layers, or in combination with them.

We have thus described electron beam induced resonance that can be used to produce visible light of optimized frequencies from a single metal layer. Such devices have application in such fields as ultra high-speed data communications and in any light producing application.

The various devices and their components described herein may be manufactured using the methods and systems described in related U.S. patent application Ser. No. 10/917,511, filed on Aug. 13, 2004, entitled “Patterning Thin Metal Film by Dry Reactive Ion Etching,” and U.S. application Ser. No. 11/203,407, filed on Aug. 15, 2005, entitled “Method Of Patterning Ultra-Small Structures,” both of which are commonly owned with the present application at the time of filing, and the entire contents of each of have been incorporated herein by reference.

Thus are described electron beam induced resonance and methods and devices for making and using same. While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. 

1. A klystron with opposing silver walls having silver wall widths of between about 41 nm and about 125 nm and defining an internal space between the silver walls of between about 47 nm and about 563 nm to electrically resonate at a frequency in excess of the microwave frequency when stimulated by a passing linear charged-particle beam.
 2. A klystron according to claim 1, wherein the internal space between the silver walls is between about 47 nm and about 108 nm.
 3. A klystron structure according to claim 1, wherein the opposing silver walls are physically connected and the internal space defines a klystron cavity.
 4. A klystron structure according to claim 1, wherein opposing silver walls define a C-shaped klystron cavity.
 5. A klystron structure according to claim 1, wherein the opposing silver walls are physically connected by another silver wall to form three sides of a klystron cavity.
 6. A klystron structure according to claim 1, wherein the silver wall widths are substantially non-uniform.
 7. A system to generate electromagnetic energy at light frequencies or higher when stimulated by an electron beam, comprising: a structure with a metal wall having at least a portion with a metal wall width of between 41 nm and 125 nm and a length of between 40 nm and 700 nm, the structure having a characteristic to generate the electromagnetic energy at light frequencies or higher when stimulated by the electron beam.
 8. A system according to claim 7, wherein the metal is silver.
 9. A system according to claim 8, wherein the metal wall and opposing metal wall define a space between them of between about 47 nm and about 563 nm.
 10. A system according to claim 9, wherein the metal wall, opposing metal wall and space define a C-shaped klystron cavity.
 11. A system according to claim 7, further including an opposing metal wall also having metal wall width of between 41 nm and 125 nm and a length of between 40 nm and 700 nm.
 12. A system according to claim 11, wherein the metal wall and opposing metal wall are not physically joined by conductive material.
 13. A system according to claim 11, wherein the metal wall and opposing metal wall are physically joined by another metal wall.
 14. A method of producing electromagnetic radiation at light frequency or higher, comprising: providing a first metallic structure having a width of between 41 nm and about 125 nm and a length of between 40 nm and 700 nm; providing a second metallic structure having a width of between 41 nm and about 125 nm and a length of between 40 nm and 700 nm, at least a portion of said second metallic structure physically spaced from the first metallic structure by no less than about 47 nm and no more than about 563 nm; passing a common electron beam within about 30 nm of a portion of the first metallic structure and within about 30 nm of a portion of the second metallic structure.
 15. A method according to claim 14, comprising the step of passing the common electron beam within about 10 nm of the first metallic structure and within about 10 nm of a portion of the second metallic structure.
 16. A method according to claim 14, comprising the step of passing the common electron beam within about 5 nm of the first metallic structure and within about 5 nm of a portion of the second metallic structure.
 17. A method according to claim 14 further including the step of: providing a third metallic structure physically connecting the first and second metallic structures.
 18. A method according to claim 17 further including the step of: providing the third metallic structure to define a cavity, the third metallic structure generally parallel to the path of the electron beam.
 19. A method according to claim 14 further including the step of: providing a plurality of first and second metallic structures, each having a width of between 41 nm and about 125 nm and a length of between 40 nm and 700 nm, some of said first and second metallic structures having length sizes different than others of said first and second metallic structures. 